Professional Documents
Culture Documents
JACOBS H&G
DOCUMENT NO:
P WI 05
NONE
Rev No.
Issue Date
Pages
Rev Description
Prepared
By
Checked
By
Approved
By
10 + 2
Annex.
For Comments
SPP
RGP
VVD
10 + 2
Annex.
SPP
RGP
VVD
/var/www/apps/conversion/tmp/scratch_7/293923885.docx
TABLE OF CONTENTS
1.0
PURPOSE
2.0
SCOPE
3.0
DEFINITIONS
4.0
METHOD (PROCEDURE)
4.1
4.2
4.3
4.4
4.5
4.6
GENERAL
FORMAT
CONTENT
VALIDATED SOFTWARE
CHECKING AND APPROVAL
ISSUING, FILING, AND STORAGE
5.0
6.0
RECORDS
7.0
ATTACHMENTS/APPENDICES
/var/www/apps/conversion/tmp/scratch_7/293923885.docx
07/11/15 05:53
1.0
PURPOSE
The purpose of this procedure is to define the workflow, format, and procedure of Shell & Tube
Heat exchanger Design by using HTRI Package.
2.0
SCOPE
This procedure applies to all Shell & Tube Heat Exchangers performed by the Process
Department.
3.0
DEFINITIONS
none.
4.0
METHOD (PROCEDURE)
4.1
GENERAL
It is the responsibility of the individual to design Shell & Tube Type heat Exchanger in
accordance with this procedure.
4.2
FORMAT
None.
4.3
CONTENT
Shell & tube Heat exchanger Design steps
Geometry
Input following configuration
TEMA type
Tube type
Plane or finned.(for shell & tube generally plane tubes are used )
Tube
length
Orientation
are used. In MKS unit we can use tube length with step of 500 mm.
Some times we suppose to use FPS std.Tube in MKS unit.
(i.e. 6096 mm,3048 mm etc.)
For small exchangers we can use tube of 1000 mm length also.
Effective Tube length
Tube OD
Generally 19.05,25.4,31.75,38.1,50.1 mm
Tube Pitch
Tube layout
30,60,45,90
Flow Direction
Flow Direction
30 O Layout
Tube passes
Tube
count
Tube material
Baffle type
Baffle cut
Flow Direction
60 O Layout
Flow Direction
90 O Layout
45 O Layout
Baffle spacing
Sealing strips
Impingement plate
For design case not required.
If Shell side nozzle inlet / outlet RV2 is more than allowed limit then HTRI will consider
Impingement plate. For gas & two phase flow Imp. Plate is required, For Liquid
Phase it depends on RV2.Generally rectangular Imp. plate are used for Exchanger.
There is some optional data, which is not required for design purpose. But this data
Should be corrected at the time of rating & fine-tuning, which is given below.
Total tube sheet thickness, Floating head support plate, Support at U-bend,
Design temperature & pressure etc.
4.3.3)
Piping
4.3.4)
Process
Exchanger Duty
Duty Multiplier
Fouling resistance
4.3.5)
4.3.6)
Composition units
Moles, mass
Flash type
Differential (Separate & not in contact), Integral (Well mixed and in thermal &
chemical equilibrium)
Design
Geometry
a)Shell ID
b)Baffle spacing
c)Tube passes
d)Tube length
/var/www/apps/conversion/tmp/scratch_7/293923885.docx07/11/15
f)Tube Diameter
g)Shell type
Duty (MM
Over
Design %
Total
Area (m2)
Baffle
Type
Sng. Seg.
Sng. Seg.
10
1.3000
20.000
4999.9
464.522
1219.20
1.632
0.836
4.50
17.76
1001.62
1466.41
12
1.3000
20.000
5999.9
477.573
863.602
1.085
1.402
6.06
19.15
1063.00
1975.51
378.15
Here you can give name of client, Exchanger, Project No. etc.
Here you can give case description (Design case, Rating Case,
With ___ Length, With ____ Shell Type etc.)
46.7
12.8518
751.001
1.58
Warnings
You can give warnings as given In HTRI
Constraints,options,warnings are not required for simple design.
Control
Name
Case
Sng. Seg.
1.3000
20.000
1000.0
1524.00
0.497
0.820
5.45
2.48
398.42
1144.24
59.0
201.06
345.75
12.8518
1349.65
45.7
12.8518
1319.87
1.66
61.50
Options
You can give constraints of Hot fluid velocity, cold fluid velocity,
Pressure drop etc.
You can give options as given In HTRI Program.
8999.9
20.000
1.3000
16
Sng. Seg.
5999.9
20.000
1.3000
12
Sng. Seg.
814.16
2280.81
542.577
1277.88
2028.59
477.573
304.86
499.95
1371.60
46.2
50.0
863.602
12.8518
12.8518
Methods,Safety,User defined methods,Vibration,F & J curve etc are not required for
Simple design.
3158.81
1.511
1.643
0.877
1.197
3.45
13.66
5.17
17.69
4.3.9)
Constraints
779.736
4.3.8)
HTRI gives various design with different shell ID with optimum baffle spacing for given
various tube length & tube passes.
HTRI gives shell ID in STD. Inch format. We are suppose to fine-tune for nearest round number
which is divisible by 5 in Rating mode.
We are varying only Tube length, No of passes in design mode.
For special case you can very all other parameters.
240.42
4.3.7)
In Design mode we are not varying Shell ID,Baffle spacing, Pitch ratio, Shell type, Baffle type.
49.41
Xist Rating 1 Shortcut Design 18 Shortcut Design 11 Shortcut Design 10 Shortcut Design 1
Case
h)Baffle type
U
Shell h
(kcal/m2Tube h
(kcal/m2Shell
Velocity
Tube
Velocity
Shell DP
(kgf/cm2)
Tube DP
(kgf/cm2)
Shells In
Series
Shells In
Parallel
Shell ID
(mm)
Baffle
Spacing
Tube
Passes
Tube
Length
Tube Dia.
(mm)
Tube
Pitch
CrossPas
ses
ShellType
e)Pitch ratio
Take printout of various designs. Analyze and evaluate % over design, Pressure drop, No of
Shell in series, No of shell in parallel, Area, H.T. Coefficient, Velocity etc.
Select one case for rating.
Select Optimum case from various design & Click right button of mouse and save input as
rating file with different file name.
Open rating file and run case again.
Analyze result for Pressure drop, Over design, Warnings, H.T.Coefficient etc.
If Over design is more then 5.0 %( Our standard) you can reduce tube nos, or tube length.
Check Flow
fractions.
a)Try to increase B-stream flow fraction and minimize leakage stream flow fractions. In actual
practice, it is not possible or necessarily desirable to eliminate leakage streams completely
because clearances are required to construct the heat exchanger. B-stream fraction
should be more than 40 %.(for viscous fluid it less & Shell side condensing fluid it is less)
B-stream can be increased by increasing baffle cut, Reducing no of baffles, and also
reducing other leakages.
b)The magnitude of the tube-to-baffle clearance affects the size of the "A" leakage stream.
Because the "A" stream is thermally effective, a significant "A" stream does not have a large
negative impact on thermal performance of the exchanger.
c)C-stream bypassing can result because of bundle to shell clearance, which can be
reduced by using sealing strips. For floating head exchanger this stream is on higher side
which can be reduced up to some extent by using sealing strIps.HTRI calculate sealing
strip pairs, but you can use one pair for every 5 tube rows which are in overlap region.
d)"E" stream is not thermally effective, a large "E" stream has a large negative impact on the
Exchangers thermal performance."E"stream is because of baffle to shell clearance.
HTRI uses TEMA Std.You can vary This clearance with the help of fabricator advise.
e)The F stream travels along tube pass partition lanes. Because these bypass streams can
affect heat transfer and pressure drop performance, they must be modeled accurately.
Thus, usually you do not run a case with these streams blocked. HTRI block this stream
by using seal rod of same OD of tube or smaller OD.
4.3.10)
Tips to decide optimum & good design of Shell & Tube Heat exchanger
a)Find out which coefficient is governing.
If shell side coefficient is governing then check All DP is used or not.
If all DP is not used then increase no of baffles or reduce Baffle cut.
If DP is Higher than allowed then reduce no of baffles or increase Baffle cut.
Some time you can go for Double segmental Baffle for very low DP in shell side.
b)When you are specifying no of baffles ensure shell side Inlet / Outlet nozzle location.
if you want shell side nozzle on opposite side then no of baffle cross passes are odd.
c)Generally for horizontal shell nozzles are on opposite side. For vertical shell Nozzle can
be on opposite side or same side.
d)Inlet / Outlet Baffle spacing is dependent on nozzle ID.Baffle should not foul nozzle.
Generally Inlet / Outlet spacing is Equal to or More than Mid Baffle Spacing.
Try to set baffle spacing divisible by 5 mm in MKS unit or 1 Inch in FPS units.
Check % Contribution of DP in Nozzle, Cross Flow. If DP In nozzle is high then go for
Higher nozzle size.
e)If shell side coefficient is very low you can increase it by using fin tube, but shell side
fluid should be very clean.(Special Design)
f)If tube side coefficient is governing then check All DP is used or not.
If all DP is not used then increase tube length & reduce no of tubes at the same time
by kipping same H.T.area.
If all DP is not used & actual DP is very less then increase tube passes.
You can go for smaller tube OD but you have to run Design mode again with two different
tube OD & fine-tune.
g)For single phase on shell side you can use vertical as well as horizontal cut baffles.
For two phase flow on shell side mostly use vertical cut baffles. some time you can use
horizontal baffles with cutout at bottom.
h)Nozzle orientation should be such that we get counter current flow in 1st tube pass.
i)U-tube exchanger is cheaper because only one tube sheet is required.
(for U-tube type exchanger Tube side cleaning is not possible.)
j)Specify Location of nozzle at U-bend for U-tube Exchanger. Options are At U-bend,
Before U-bend & After U-bend.
/var/www/apps/conversion/tmp/scratch_7/293923885.docx07/11/15
Procedure for preparing Shell & Tube heat exchanger process data sheet
First copy standard Shell & Tube Heat exchanger process data sheet from standard format.
a) Read following points when updating standard process data sheet.
a1)
Marked cells to be checked / rewritten / deleted as per requirement.
b1) Please note that for fixed tube-sheet exchanger mean metal temperature to be given for
various conditions as in sheet-4.
c1) Copy Tube Layout from HTRI output on sheet-6.
d1) When Shells in series are more than one, then we are supposed to give detailed
Interconnection drawing on separate sheet.(sheet-3)
e1) When Shells in series are more than one & MOC for Tubes & Shells are different for
different shells then give table for MOC.( sheet-3 )
f1) If we require Duty or Flow margin then we are supposed to specify in remark.
G1) For double segmented baffle there is no provision to specify cut for inner baffle
& outer baffle. We suppose to include this point in to remarks.
h1) There is no provision in HTRI to specify whether Exchanger is IBR approved or not.
We suppose to include this point in remarks.
b)Copy from TEMA-1 Sheet from Row -9 to Row-58 & Paste only the Values at
location given in standard data sheet.(Sheet-2)
c)Copy Sketch of Individual shell from individual & connect to each other.(Sheet-3)
Please check inlet & outlet nozzle location are correctly shown for shell side & Tube side.
This sheet is required when there are more than one shells in series or parallel.
In Design pressure, Design temperature, Material of construction are different for different shell then
Specify in Sheet-3.
d)Mean Metal Temperature : This is required For Fixed Tube Sheet Exchangers Only. If no of shells
in series are more than one then we are supposed to specify mean metal temperature for All shell's.
Specify Nozzle schedule in Sheet-4.
e)Draw sketch of reboiler & piping details in Sheet-5.
Sheet-5 is required when Exchanger is reboiler & piping details are required to ensure
pressure drop in inlet / outlet Piping.
f)Copy Tube layout from HTRI Output (Drawing-Tube layout) & paste in Sheet-6.
If tube layout is not fitting width wise then reduce size of tube layout by changing object size.
Remove Shell side nozzle ID from tube layout. We are specifying nozzle schedule in Sheet-4.
g)Delete Sheets & data depending on type of exchanger.
4.4
SOFTWARE
This work instruction is prepared for Shell & Tube type Heat exchanger by using HTRI
package.
4.5
4.6
5.0
6.0
RECORDS
Calculation no to be given to Shell & Tube Heat Exchanger Design.
7.0
ATTACHMENTS / APPENDICES
7.1 Standard Process data sheet for Shell & tube heat exchanger.
"Standard Data
Sheet For Shell & Tube Heat Exchanger.xls "
/var/www/apps/conversion/tmp/scratch_7/293923885.docx07/11/15